Heat Controller BG-101A User manual

Brand: Heat Controller

Model: BG-101A

Category: Split-system air conditioners

Type: User manual

This manual is also suitable for

Through-The-Wall

Air Conditioner

Service Manual

CAUTION

-Before servicing the unit, read the "safety precautions" in this manual.

-Only for authorized service personnel.

HEAT CONTROLLER, INC.

MODELS: BG-81A

BG-101A

BG-123A

—2—

1. PREFACE

1.1 SAFETY PRECAUTIONS ...............................2

1.2 INSULATION RESISTANCE TEST.................2

1.3 SPECIFICATIONS ..........................................3

1.4 FEATURES.....................................................4

1.5 CONTROL LOCATIONS.................................4

DISASSEMBLY INSTRUCTIONS

2.1 MECHANICAL PARTS....................................5

2.1.1 FRONT GRILLE.....................................5

2.1.2 CABINET................................................5

2.1.3 CONTROL BOX.....................................5

2.2 AIR HANDLING PARTS..................................6

2.2.1

ORIFICE, HEATER ASSY AND TURBO FAN

.........6

2.2.2 FAN........................................................6

2.2.3 SHROUD................................................7

2.3 ELECTRICAL PARTS.....................................7

2.3.1 MOTOR..................................................7

2.3.2 COMPRESSOR .....................................7

2.3.3 CAPACITOR ..........................................7

2.3.4 POWER CORD......................................8

2.3.5 THERMISTOR .......................................8

2.4 REFRIGERATION CYCLE.................................9

2.4.1 CONDENSER ......................................9

2.4.2 EVAPORATOR ....................................9

2.4.3 CAPILLARY TUBE...............................9

INSTALLATION

3.1 INSTALLATION REQUIREMENTS...............12

3.2 INSTALLATION.............................................13

3.3 PROCEDURE A............................................14

3.4 PROCEDURE B............................................15

3.5 PROCEDURE C............................................17

TROUBLESHOOTING GUIDE

4.1 OUTSIDE DIMENSIONS...............................19

4.2 PIPING SYSTEM ..........................................19

4.3 TROUBLESHOOTING GUIDE......................20

5. SCHEMATIC DIAGRAM

5.1 CIRCUIT DIAGRAM......................................25

1. PREFACE

This SERVICE MANUAL provides various service information, including the mechanical and electrical

parts etc. This room air conditioner was manufactured and assembled under a strict quality control system.

The refrigerant is charged at the factory. Be sure to read the safety precautions prior to servicing the unit.

1.1 SAFETY PRECAUTIONS

1. When servicing the unit, turn off the air conditioner

and unplug the power cord.

2. Observe the original lead dress.

If a short circuit is found, replace all parts which

have been overheated or damaged by the short

circuit.

3. After servicing the unit, make an insulation

resistance test to protect the customer from being

exposed to shock hazards.

1.2

INSULATION RESISTANCE TEST

1. Unplug the power cord and connect a jumper

between 2 pins (black and white).

2. The grounding conductor (green or green & yellow)

is to be open.

3. Measure the resistance value with an ohm meter

between the jumpered lead and each exposed

metallic part on the equipment.

4. The value should be over 1MΩ.

CONTENTS

BG-101A

—3—

1.3 SPECIFICATIONS

1.3.1FOR BG-81A/BG-101A/BG-123A

POWER SUPPLY

COOLING CAPACITY (Btu/h)

INPUT (W)

RUNNING CURRENT (A)

E.E.R (Btu/w.h)

REFRIGERANT (R-22) CHARGE(g)

OPERATING

INDOOR (°C)

TEMPERATURE

OUTDOOR (°C)

EVAPORATOR

CONDENSER

FAN, INDOOR

FAN, OUTDOOR

FAN SPEEDS, FAN/COOLING

FAN MOTOR

OPERATION CONTROL

ROOM TEMP. CONTROL

AIR DIRECTION CONTROL

CONSTRUCTION

PROTECTOR COMPRESSOR

FAN MOTOR

POWER CORD

DRAIN SYSTEM

NET WEIGHT (lbs/kg)

DIMENSION (inch)

(W x H x D) (mm)

SLEEVE DIMESION (inch)

(W x H x D) (mm)

SLEEVE DEPTH (inch)

WITH FRONT GRILLE (mm)

1Ø, 115V, 60Hz

9,800 11,500/11,200 8,000

1,110 1,310/1270 830

10.2 6.0/6.4 7.5

8.8 8.8/8.8 9.6

470g(16.6OZ) 485g(17.1OZ) 545g(19.2OZ)

26.7(DB) 19.4(WB)

35(DB) 23.9(WB)

3 ROW 12STACKS 2ROW12STACKS

1ROW 17STACKS, L-BENDING TYPE

TURBO FAN

PROPELLER TYPE FAN WITH SLINGER-RING

3/3

4POLES

ELECTRIC

THERMISTOR

VERTICAL LOUVER(RIGHT & LEFT)

HORIZONTAL LOUVER(UP & DOWN)

TOP-DOWN

EXTERNAL OVERLOAD PROTECTOR

INTERNAL THERMAL PROTECTOR

2.3m (3WIRES WITH GROUNDING)

ATTACHMENT PLUG(CORD-CONNECTED TYPE, LCDI)

SPLASHED BY FAN SLINGER

78/35 80/36 73/33

24 x 14

/32 x 20

/32

610 x 366 x 499

/8 x 15

/32 x 16

/32

656 x 394 x 425

521

MODELS

REMARK

ITEMS

OPTIONAL

PART

LOUVERED-FIN TYPE

BG-81A

BG-123A

1Ø, 115V, 60Hz1Ø, 230/208V, 60Hz

1.4 FEATURES

• Designed for cooling only.

• Powerful and quiet cooling.

• Top-down chassis for the simple installation and service.

1.5 CONTROL LOCATIONS

1.5.1 COOLING ONLY MODEL

• OPERATION

• Side air-intake, side cooled-air discharge.

• Built in adjustable THERMISTOR and THERMOSTAT.

• Washable one-touch filter.

• Compact size.

• VENTILATION

Push the lever to the "CLOSE" position to cool, heat or recirculate room air only.

Pull the lever to the "OPEN" position to exhaust smoke or stale air from the room.

This feature is best used in conjunction with the FAN ONLY position.

—4—

PULL OPEN / PUSH CLOSE

MODE TIMER POWER

FAN

SPEED

Fan

Energy

Saver

Cool

Timer

TEMP

F1 LOW

F2 MED

F3 HIGH

REMOTE CONTROL SIGNAL RECEIVER

POWER

MODE

Push this button to shift mode of operation from COOL → ENERGY SAVER → FAN.

- COOL:

• Fan runs continually for normal cooling operation.

- ENERGY SAVER:

• The fan stops when the compressor stops cooling. Approximately every 3 minutes the fan will turn on and the unit will check the room air

temperature to determine if cooling is needed.

- FAN:

• Fan-only operation.

TIMER

- SHUT-OFF TIME

• You will usually use shut-off time while you sleep.

• If unit is running, use Timer to set number of hours until shut-off.

• For your sleeping comfort, once Time is set, the Temperature setting will raise 2°F after 30 min., and once again after another 30 min.

• Push Timer button to advance setting from 1Hour → 2Hours → ... → 12Hours maximum.

- START TIME

• If unit is off, use Timer to set number of hours before unit starts.

• Push Timer button to advance setting from 1Hour → 2Hours → ... → 12Hours maximum.

TEMPERATURE SETTING

• Use this button to automatically control the temperature of the room.

The temperature can be set within a range of 60°F to 86°F by increments of

1°F.

• The setting appears in the display.

• To turn the air conditioner ON, push this button.

To turn the air conditioner OFF, push the button again.

• This button takes priority over any other button.

• When you first turn it on, the unit is in cool mode, High fan speed,

Temperature setting at 72°F.

FAN SPEED

• Every time you push this button, it advances the setting as follows:

{High → Low → Med → High}

When the air conditioner has been operating in the

cooling and is turned off or set to the fan only position,

wait at least 3 minutes before resetting to the cooling

operation again.

CAUTION

—5—

2.1 MECHANICAL PARTS

2.1.1 FRONT GRILLE

1. Open the inlet grille downward.

2. Remove the screw which fastens the front grille.

3. Pull the front grille from the right side.

4. Remove the front grille. (See Fig. 1)

5. Re-install the component by referring to the

removal procedure.

2.1.2 CABINET

1. After disassembling the FRONT GRILLE, remove

the 6 screws which fasten the cabinet at the both

sides and the top. (See Fig. 2)

Keep these for later use.

2.1.3 CONTROL BOX

1. Remove the front grille. (Refer to section 2.1.1)

2. Remove the screw which fasten the control

box. (See Fig. 3)

3. Pull the control box from the barrier.(See Fig.3)

4. Discharge the capacitor by placing a 20,000 ohm

resistor across the capacitor terminals.

5. Disconnect two wire housings in the control box.

6. Pull the control box forward completely.

7. Re-install the components by referring to the

removal procedure. (See Fig. 3)

(Refer to the circuit diagram found on pages 25 in

this manual and on the control box.)

2. DISASSEMBLY INSTRUCTIONS

— Prior to disassembling the unit, make sure that the POWER is off and the power cord is unplugged from the

wall receptacle.

MODE

TIMER

POW

FAN

SPEED

Fan

Energy

Saver

Cool

Timer

TEMP

F1 LOW

F2 MED

F3 HIGH

Figure 1

Figure 2

MODE

TIMER

POWER

FAN

SPEED

Fan

Energy

Saver

Cool

Timer

TEMP

F1 LOW

F2 MED

F3 HIGH

FAN

SPEED

Fan

Cool

Timer

TEMP

MODE TIMER POWER

FAN

SPEED

Fan

Energy

Saver

Cool

Timer

TEMP

F1 LOW

F2 MED

F3 HIGH

Figure 3

Figure 7

—6—

2.2 AIR HANDLING PARTS

2.2.1 ORIFICE, AND TURBO FAN

1. Remove the front grille. (Refer to section 2.1.1)

2. Remove the cabinet. (Refer to section 2.1.2)

3. Remove the 2 screws which fasten the

evaporator at the left side and the right side.

(See Fig. 4)

4. Move the evaporator sideward carefully.

5. Remove the orifice. (See Fig. 5)

8. Using handheld pliers, remove the clamp which

secures the turbo fan. (See Fig. 6)

9. Remove the turbo fan with pliers or your hand,

without touching blades. (See Fig. 7)

10. Re-install the components by referring to the

removal procedures, above.

2.2.2 FAN

1. Remove the cabinet. (Refer to section 2.1.2)

2. Remove the brace.

(Refer to section 2.2.1)

3. Remove the 7 screws which fasten the condenser.

4. Move the condenser sideways carefully.

5. Using handheld pliers, remove the clamp which

secures the fan.

6. Remove the fan. (See Fig. 8)

7. Re-install the components by referring to the

removal procedures, above.

TIM

FAN

SPEED

Fan

Energy

Saver

Cool

Tim

TEMP

F1 LOW

F2 MED

F3 HIGH

MODE

TIMER

POWER

FAN

SPEED

Fan

ergy

Saver

Cool

Timer

TEMP

1 LO

F2 MED

F3 H

TIMER

FAN

SPEED

Fan

nergy

Saver

ool

Tim

TEMP

F1 LOW

F2 MED

F3 HIGH

Figure 4

Figure 5

Figure 6

TIM

POW

FAN

SPEED

Fan

Energy

Saver

Cool

Tim

TEMP

F1 LOW

F2 MED

F3 HIGH

Figure 8

—7—

2.2.3 SHROUD

1. Remove the fan. (Refer to section 2.2.2)

2. Remove the shroud. (See Fig. 9)

3. Re-install the components by referring to the

removal procedures, above.

2.3 ELECTRICAL PARTS

2.3.1 MOTOR

1. Remove the cabinet. (Refer to section 2.1.2)

2. Remove the clamp cord and disconnect the wire

housing in control box. (Refer to section 2.1.3)

3. Remove the turbo fan. (Refer to section 2.2.2)

4. Remove the fan. (Refer to section 2.2.2)

5. Remove the 4 or 2 screws which fasten the motor.

(See Fig. 10)

6. Remove the motor.

7. Re-install the components by referring to the

removal procedures, above.

2.3.2 COMPRESSOR

1. Remove the cabinet. (Refer to section 2.1.2)

2. Discharge the refrigerant system using a Freon

Recovery System.

If there is no valve to attach the recovery system

to, install one (such as a WATCO A-1) before

venting the Freon

. Leave the valve in place after

servicing the system.

3. Disconnect the 3 leads from the compressor.

4. After purging the unit completely, unbraze the

suction and discharge tubes at the compressor

connections.

5. Remove the 3 nuts and the 3 washers which

fasten the compressor. (See Fig. 11)

6. Remove the compressor.

7. Re-install the components by referring to the

removal procedures, above.

2.3.3 CAPACITOR

1. Remove the control box. (Refer to section 2.1.3)

2. Remove the 1 screw

3. Open the control box

4. Disconnect all the leads on the capacitor terminals.

5. Re-install the components by referring to the

removal procedures, above.

MODE

TIMER

POWER

FAN

SPEED

Fan

Energy

Saver

Cool

Timer

TEMP

F1 LOW

F2 MED

F3 HIGH

Figure 9

Figure 10

Figure 11

Figure 12

—8—

2.3.4 POWER CORD

1. Remove the control box. (Refer to section 2.1.3)

2. Unfold the control box. (Refer to section 2.3.3)

3. Disconnect the grounding screw from the Base

pan.

4. Disconnect 2 receptacles.

5. Remove a screw which fastens the clip cord.

6. Pull the power cord. (See Fig. 13)

7. Re-install the components by referring to the

removal procedure, above.

(Use only one ground-marked hole, , for ground

connection.)

8. If the supply cord of this appliance is damaged, it

must be replaced with the factory-authorized and

specified cord.

2.3.5 THERMISTOR

1. Remove the control box. (Refer to section 2.1.3)

2. Unfold the control box. (Refer to section 2.3.3)

3. Disconnect all the leads of thermistor terminals.

4. Remove the thermistor. (See Fig. 14)

5. Re-install the components by referring to the

removal procedures, above.

MODE

TIMER

POWER

FAN

SPEED

Fan

Energy

Saver

Cool

Timer

TEMP

F1 LOW

F2 MED

F3 HIGH

Figure 13

Figure 14

—9—

2.4 REFRIGERATION CYCLE

2.4.1 CONDENSER

1. Remove the cabinet. (Refer to section 2.1.2)

2. Remove the brace.

(Refer to section 2.2.1)

3. Remove the 7 screws which fasten the condenser.

4. After discharging the refrigerant completely into a

Freon

Recovery System, unbraze the

interconnecting tube at the condenser

connections.

5. Remove the condenser.

6. Re-install the components by referring to the notes

(See Fig. 15)

2.4.2 EVAPORATOR

1. Remove the cabinet. (Refer to section 2.1.2)

2. Discharge the refrigerant completely – into a

Freon

Recovery System.

3. Remove the 2 screws which fasten the evaporator

at the left side and the right side.

4. Move the evaporator sideward carefully and then

unbraze the interconnecting tube at the evaporator

connectors.

5. Remove the evaporator.

6. Re-install the components by referring to the notes

(See Fig. 16)

2.4.3 CAPILLARY TUBE

1. Remove the cabinet. (Refer to section 2.1.2)

2. After discharging the refrigerant completely – into

a Freon

Recovery System, unbraze the

interconnecting tube at the capillary tube.

3. Remove the capillary tube.

Re-install the components by referring to the notes.

Figure 15

Figure 16

FAN

SPEED

Fan

Energy

Saver

Cool

Timer

TEMP

F1 LOW

F2 MED

F3 HIGH

Discharge the refrigerant system using a Freon

Recovery System.

If there is no valve to attach the recovery system,

install one (such as a WATCO A-1) before

venting the Freon

. Leave the valve in place

after servicing the system.

CAUTION

—10—

— Replacement of the refrigeration cycle.

1. When replacing the refrigeration cycle, be sure to

discharge the refrigerant system using a Freon

recovery System.

If there is no valve to attach the recovery system,

install one (such as a WATCO A-1) before venting

the Freon

. Leave the valve in place after

servicing the system.

2. After discharging the unit completely, remove the

desired component, and unbrace the pinch-off

tubes.

3. Solder service valves into the pinch-off tube ports,

leaving the valves open.

4. Solder the pinch-off tubes with Service valves.

5. Evacuate as follows.

1) Connect the vacuum pump, as illustrated Fig.

17A.

2) Start the vacuum pump, slowly open manifold

valves A and B with two full turns

counterclockwise and leave the valves closed.

The vacuum pump is now pulling through valves

A and B up to valve C by means of the manifold

and entire system.

3) Operate the vacuum pump for 20 to 30 minutes,

until 600 microns of vacuum is obtained. Close

valves A and B, and observe vacuum gauge for

a few minutes. A rise in pressure would

indicate a possible leak or moisture remaining in

the system. With valves A and B closed, stop

the vacuum pump.

4) Remove the hose from the vacuum pump and

place it on the charging cylinder. See Fig. 17B.

Open valve C.

Discharge the line at the manifold connection.

5) The system is now ready for final charging.

6. Recharge as follows :

1) Refrigeration cycle systems are charged from the

High-side. If the total charge cannot be put

in the High-side, the balance will be put in the

suction line through the access valve which you

installed as the system was opened.

Connect the charging cylinder as shown in Fig. 17B.

With valve C open, discharge the hose at the

manifold connection.

3) Open valve A and allow the proper charge to

enter the system. Valve B is still closed.

4) If more charge is required, the high-side will not

take it. Close valve A.

5) With the unit running, open valve B and add the

balance of the charge.

a. Do not add the liquid refrigerant to the Low-

side.

b. Watch the Low-side gauge; allow pressure to

rise to 30 lbs.

c. Turn off valve B and allow pressure to drop.

d. Repeat steps B and C until the balance of the

charge is in the system.

6) When satisfied the unit is operating correctly,

use the pinch-off tool with the unit still running

and clamp on to the pinch-off tube. Using a tube

cutter, cut the pinch-off tube about 2 inches from

the pinch-off tool. Use sil-fos solder and solder

pinch-off tube closed. Turn off the unit, allow it to

set for a while, and then test the leakage of the

pinch-off connection.

NOTES

If high vacuum equipment is used, just crack

valves A and B for a few minutes, then open

slowly with the two full turns counterclockwise.

This will keep oil from foaming and being

drawn into the vacuum pump.

CAUTION

—11—

Equipment needed: Vacuum pump, Charging cylinder, Manifold gauge, Brazing equipment. Pinch-off tool

capable of making a vapor-proof seal, Leak detector, Tubing cutter, Hand Tools to remove components, Service

valve.

COMPOUND GAUGE

EVAPORATOR

(LOW PRESSURE SIDE)

COMPRESSOR

CAPILLARY TUBE

CONDENSER

(HIGH PRESSURE SIDE)

SEE INSETS

BELOW

MANIFOLD

GAUGE

Figure 17A-Pulling Vacuum

Figure 17B-Charging

EXTERNAL

VACUUM PUMP

CHARGING

CYLINDER

LOW

—12—

3. INSTALLATION

3.1 INSTALLATION REQUIREMENTS

If you use an existing wall sleeve, you should measure its

dimensions.

Install the new air conditioner according to these installation

instructions to achieve the best performance. All wall sleeves

used to mount the new air conditioner must be in good

structural condition and have a compatible rear grille in order

to securely attach the new air conditioner. (FIG. 18A)

With the FRIEDRICH USC sleeve, you can maintain the

best performance of the new air conditioner. (FIG. 18B)

ELECTRICAL SERVICE

Check your available electrical service. The power supply

available must be the same as that shown on the unit

nameplate (found on left side of cabinet).

All models are equipped with a 3-prong service plug to

provide proper service and safe positive grounding. Do not

change plug in any way. Do not use an adapter plug. If your

present wall outlet does not match your plug, call a qualified

electrician to make the necessary corrections. SAVE

CARTON for storage and this OWNER'S MANUAL for future

reference. The carton is the best way to store unit during

winter or when not in use.

INSTALLATION HARDWARE

To avoid risk of personal injury, property damage, or

product damage due to the weight of this device and sharp

edges that may be exposed:

• Air conditioners covered in this manual pose an

excessive weight hazard. Two or more people are

needed to move and install the unit.

To prevent injury or strain, use proper lifting and carrying

techniques when moving unit.

• Carefully inspect location where air conditioner will be

installed. Be sure it will support the weight of the unit

over an extended period of time.

• Handle air conditioner with care. Wear protective gloves

whenever lifting or carrying the unit. AVOID the sharp

metal fins of front and rear coils.

• Make sure air conditioner does not fall during installation.

CAUTION

REQUIRED TOOLS:

• Tight Fitting gloves

• Standard screwdriver

• Phillips screwdriver

• Pliers

• Sharp knife

• 3/8-inch open end

wrench or adjustable

wrench

• 1/4-inch hex socket

and ratchet

• Tape measure

• Electric drill

• 1/4-inch drill bit

14-

(366 mm)

24"(610 mm)

18-

"(468 mm)

20-

(511 mm)

FIG. 18A

Air Conditioner

15-

/32"

(394 mm)

16-

/32"

(425 mm)

25-

/8"

(656 mm)

aluminum metal grille

FIG. 18B

FRIEDRICH USC Wall Sleeve

ITEM NAME OF PARTS Q'TY

PLASTIC GRILLE 1

VERTICAL INSULATION STRIP 1

AROUND INSULATION STRIPS 2

HORIZONTAL INSULATION STRIP 1

SUPPORT BLOCK 2

BAFFLE 1

TRIM FRAME 2

SHIM 2

PLASTIC NUTS AND WASHER SCREWS

2 4

2 Size options

—13—

3.2 INSTALLATION

• Pick a location which will allow the conditioned air to blow

into the area you want. Good installation with special

attention to the proper position of the unit will lessen the

chance that service will be needed.

ITEMS IN INSTALLATION HARDWARE

You may not need all parts in the kit. Discard unused parts

HOW TO INSTALL

Before installing the unit, identify the existing wall sleeve

from the list below.

NOTE: All wall sleeves used to mount the new Air

Conditioner must be in sound structural condition and have a

rear grille that securely attaches to sleeve, or rear flange that

serves as a stop for the Air Conditioner.

Remove old air conditioner from existing wall sleeve.

Clean the interior of an existing sleeve.

(Do not disturb seals.)

Wall sleeve must be securely fastened in wall before

installing the air conditioner. Use the nails or screws

through sleeve into wall, if needed. Repaint sleeve if

needed.

Prepare the wall sleeve for installation of the unit. If you

plan to use your existing wall sleeve, and it is not

FRIEDRICH, use procedure B or C below.

Install new unit into wall sleeve.

CAUTION: When installation is completed, replacement unit

MUST have a rearward slope as shown. To achieve 1/4"

slope, remove the backing from the 11-13/16" shim strips and

attach them as shown below in Fig. 19. Place the higher

portion of shim to the front of the rib on base of wall sleeve.

1/4"

Wall Sleeve

FRONT

UNIT

SHIM PLACEMENT UNIT INSTALLATION

1" high

" High

Shim

6" 6"

FIG. 19

Installing the Heat Controller sleeve ensures

optional performances of the unit.

If you decide to keep the existing wall sleeve, you have

to redirect the louvers at the back of the wall sleeve.

Refer to FIG. 23 on p15. The use of pliers is

recommended. If you DO NOT redirect, you run the risk

of poor performance or premature product failure. This

is not covered under the terms of the Heat Controller

warranty.

Procedure Brand

Depth(inches)

A(page 16)

FRIEDRICH USC 16-23/32

White-Westinghouse

Frigidaire Carrier

16, 17-1/2

(52F series)

or 22

General Electric

16-7/8

/Hotpoint

Whirlpool 17-1/8 or 23

Carrier (51S series)

18-5/8

Fedders/Emerson 16-3/4

Friedrich WSC or 19-3/4

Emerson/Fedders 15

(pages 17~18)

(pages 19)

ITEM (inches) Qty.

Plastic grille 26

x 16

Vertical insulation strip 15

x 1

Around Insulation Strips

x 1

Horizontal Insulation Strip 23

/32 x 1

x 1

/16 1

Support Block 1

x 1

x 4

Baffle

14 x

Shim 11

x 1 x

Trim Frame 2

Washer Screw 4

Nuts(Plastic) 4

Grille Rear 1

CAUTION

Wall Sleeve Dimensions (inches)

Brand

Width Height Depth

White-Westinghouse

25-1/2 15-1/4

16, 17-1/2

Frigidaire

or 22

Carrier (52F series)

General Electric

26 15-5/8 16-7/8

/Hotpoint

Whirlpool 25-7/8 16-1/2

17-1/8

or 23

Fedders/Emerson

27 16-3/4

16-3/4

Friedrich WSC or 19-3/4

FRIEDRICH USC 25-7/8 15-17/32 16-23/32

Emerson/Fedders 26-3/4 15-3/4 15

Carrier (51S Series) 25-3/4 16-7/8 18-5/8

PROCEDURE

If you are using the new sleeve (optionally

suppliedwithyourunit),skiptostep3.

Otherwise, install the plastic grille from the kit.

Cut the plastic grille to 25-1/2" wide and

15-1/4" high. Place the plastic grille to the

inside of the wall sleeve at the rear flange.

Fasten the 4 washer screws to secure the grille

to the wall sleeve. If you need plastic nuts to

mount plastic grille to the inside of the wall

sleeve, there are plastic nuts in the installation

kit. The nuts are installed from the inside of the

sleeve and are pressing into the square holes

of the rear flanges.Fasten the bracket to the

upside of the wall sleeve using the washer

screw. The bracket prevents the unit from

leaving the sleeve.

Remove the backing from the Vertical

Insulation strip 15

and attach that

totheinsiderightofthesleeveasshown

below. Remove the backing from the Around

Insulation strip 67

and attach that

to the inside front of the sleeve as shown

below.

FIG.20

Around Insulation

"6"

Indoor Outdoor

FIG. 22

Bracket Bracket

FIG.21

Fasten the screws and the bracket

Wall

Trim (2 ea)

FIG.23

• Air conditioners covered in this manual pose an

excessive weight hazard. Two or more people are

needed to move and install the unit.

To prevent injury or strain, use proper lifting and

carrying techniques when moving unit.

• When handling the air conditioner, be careful to avoid

cuts from sharp metal fins on front and rear coils.

• Make sure air conditioner does not fall during

removal.

• If unit does not operate after installation check, to be

sure the circuit interrupter has not been tripped. Refer

to the Troubleshooting guide for reset procedure.

CAUTION

Install the new unit into the wall sleeve.

Toassembletrim,tpthetabofeachpiece

into the slot of the other piece as shown below.

Slide trim over the front of the air conditioner

until trim is flush with sleeve as shown below.

—14—

—15—

PROCEDURE B

Redirect the louvers at the back of the wall

sleeve to 60° angle as shown in the FIG 8. The

use of pliers is recommended.

If the wall sleeve already has a rear grille, skip

to step 4. If the wall sleeve does not have a rear

grille or louvered panel, install the plastic grille

from the kit. Cut the plastic grille to 25-1/2" wide

and 15-1/4" high. Place the plastic grille to the

inside of the wall sleeve at the rear flange.

Fasten the 4 washer screws to secure the grille

to the wall sleeve. If you need plastic nuts to

mount plastic grille to the inside of the wall

sleeve, there are plastic nuts in the installation

kit. The nuts are installed from the inside of the

sleeve and are pressed into the square holes of

the rear flanges.Fasten the bracket to the

upside of the wall sleeve using the washer

screw. The bracket prevents the unit from

leaving the sleeve.

Remove the backing from the Vertical Insulation

strip 15

and attach that to the

inside right of the sleeve as shown below.

Remove the backing from the Around Insulation

strip 67

and attach that to the

inside front of the sleeve as shown below.

If the depth of your existing wall sleeve is less

than or equal to 18", skip to step 7. Otherwise,

FIG.25

Around Insulation

Vertical Insulation

"6"

Indoor Outdoor

FIG. 27

Bracket Bracket

FIG. 26

Rear Louvers

(Top View)

60°

Rear Louvers

(Top View)

60°

FIG.24

Depth"D" of the existing

wall sleeve (inches)

Length "A"

(inches)

Support

Block

Baffle

18 D 18-

18-

D 19-

19-

/4 D 22

Depth"D" of the existing

wall sleeve (inches)

Length "A"

(inches)

Place the plastic grille

Fasten the screws and the bracket

cut the baffles and the support blocks according

to length "A" in the table below.

FIG. 28

Around Insulation

Vertical Insulation

18 D 18-

18-

D 19-

"6"

Indoor Outdoor

19-

/4 D 22

—16—

PROCEDURE B CONTINUED

Remove the backing from the support blocks and attach

them to the inside of the wall sleeve as shown FIG 29.

Slide the baffle into slots of the support blocks.

Install the new unit into the wall sleeve.

Assemble trim as described in Step 6,

Procedure A.

Wall

Sleeve

Baffle

(

)

Front

Support

Block

FIG. 29

• Air conditioners covered in this manual pose an

excessive weight hazard. Two or more people are

needed to move and install the unit.

To prevent injury or strain, use proper lifting and carrying

techniques when moving unit.

• When handling the air conditioner, be careful to avoid

cuts from sharp metal fins on front and rear coils.

• Make sure air conditioner does not fall during removal.

• If unit does not operate after installation check, to be sure

the circuit interrupter has not been tripped. Refer to the

Troubleshooting guide for reset procedure.

CAUTION

—17—

Depth"D" of the existing

wall sleeve (inches)

Length "A"

(inches)

Support

Block

Baffle

18 D 18-

18-

D 19-

19-

/4 D 22

FIG. 34

3.5 PROCEDURE C

Redirect the louvers at the back of the wall sleeve to 60°

angle as shown in the FIG 30. The use of pliers is

recommended.

If the wall sleeve already has a rear grille, skip to step 4. If the

wall sleeve does not have a rear grille or louvered panel, install

the plastic grille from the kit. Cut the plastic grille to 26-1/2"

wide and 15-1/2" high or to the sleeve dimensions. Place the

plastic grille to the inside of the wall sleeve at the rear flange.

Fasten the 4 washer screws to secure the grille to the

wall sleeve. If you need plastic nuts to mount plastic grille

to the inside of the wall sleeve, there are plastic nuts in

the installation kit. The nuts are installed from the inside

of the sleeve and are pressed into the square holes of

the rear flanges. Fasten the bracket to the upside of the

wall sleeve using the washer screw. The bracket

prevents the unit from leaving the sleeve.

Remove the backing from the Horizontal Insulation strip

x 1

and attach that to the inside right of the

sleeve as shown below. Remove the backing from the

Around Insulation strip 59

x 1

and attach that

to the inside front of the sleeve as shown below.

If the depth of your existing sleeve is less than or equal

to 18”, skip to step 7. Otherwise, cut the baffles and the

support blocks according to Length "A" in the table

below.

Remove the backing from the support blocks and attach

them to the inside of the wall sleeve as shown FIG 35.

Slide the baffle into slots of the support blocks

Wall

Sleeve

Baffle

Front

Support

Block

FIG. 35

FIG. 31

Bracket Bracket

FIG. 32

Rear Louvers

(Top View)

60°

FIG. 30

Place the plastic grille

Fasten the screws and the bracket

Indoor Outdoor

Around Insulation

Horizontal Insulation

FIG. 33

—18—

1" high

" High

Shim (2EA)

6" 6"

FIG. 37

• Air conditioners covered in this manual pose an

excessive weight hazard. Two or more people are

needed to move and install the unit.

To prevent injury or strain, use proper lifting and

carrying techniques when moving unit.

• When handling the air conditioner, be careful to avoid

cuts from sharp metal fins on front and rear coils.

• Make sure air conditioner does not fall during

removal.

• If unit does not operate after installation check, to be

sure the circuit interrupter has not been tripped. Refer

to the Troubleshooting guide for reset procedure.

CAUTION

Parts and Installation

PROCEDURE C CONTINUED

To achieve rearward slope for unit draining,

remove the backing from the 11

"shim

strips and attach them as shown below in Fig.

37. The

higher portion of shim is to be placed

in front of the rib on the base of wall sleeve.

Install the new unit into the wall sleeve

Assemble trim as described in Step 6,

Procedure A.

FIG. 36

—19—

4. TROUBLESHOOTING GUIDE

4.1 OUTSIDE DIMENSIONS

20-

/32"

(499mm)

24"

(610mm)

14-

/32"

(366mm)

MODE TIMER POWER

FAN

SPEED

Fan

Energy

Saver

Cool

Timer

TEMP

F1 LOW

F2 MED

F3 HIGH

CONDENSER COILS

EVAPORATOR COILS

FAN

MOTOR

: REFRIGERANT FLOW

TURBO FAN

CAPILLARY TUBE

COMPRESSOR

4.2 PIPING SYSTEM

Following is a brief description of the important components and their functions in the refrigeration system.

Refer to Fig. 41 to follow the refrigeration cycle and the flow of the refrigerant in the cooling cycle.

MOTOR

COMPRESSOR

OIL

(LIQUID REFRIGERANT)

CAPILLARY TUBE

OUTSIDE COOLING

AIR FOR REFRIGERANT

PASS THROUGH

SUCTION LIME

COOL LOW PRESSURE VAPOR

COOLED

AIR

COMPLETE LIQUID

BOIL OFF POINT

LIQUID

PRESSURE

DROP

ROOM AIR HEAT LOAD

VAPOR INLET

HOT

DISCHARGED

AIR

LIQUID OUTLET

HIGH PRESSURE VAPOR

LIQUID PEFRIGERANT

LOW PRESSURE VAPOR

ROOM AIR CONDITIONER

EVAPORATOR COILS CONDENSER COILS

CYCLE OF REFRIGERATION

Figure 41

—20—

4.3 TROUBLESHOOTING GUIDE

In general, possible trouble is classified in two causes.

The one is called Starting Failure which is caused from an electrical defect, and the other is Ineffective Air

Conditioning caused by a defect in the refrigeration circuit and improper application.

Unit is running but cooling is ineffective

Ineffective Cooling

Check outdoor coil

(heat exchanger) & the fan

operation.

Check gas leakage.

Repair gas leak.

Replacement of unit if the

unit is beyond repair.

Satisfactory operation with

temperature difference of

inlet & outlet air ; 44.6~50˚F

Check heat load increase.

Unexpected residue

Overloaded Circuit

Check inside gas pressure.

Adjusting of refrigerant

charge

Malfunction of compressor

Replacement of

compressor

Check cold air circulation

for smooth flow.

Dirty indoor coil

(Heat exchanger)

Malfunction of fan

Clogged air filter

Obstruction at air outlet

Correct above troubles

Stop auto air-swing

Check clogging in

refrigeration circuit.

Repair clogging in

refrigeration circuit.

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Heat Controller BG-101A User manual

Brand: Heat Controller

Model: BG-101A

Category: Split-system air conditioners

Type: User manual

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Heat Controller BG-101A User manual

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